- Replacement of No. 1 HV supply stack sub-assembly
- Replacement of No. 2 HV supply stack sub-assembly
| Last Modified: 05-08-2025 | 6.11:8.1.0 | Doc ID: RM100000001WM5U |
| Model Year Start: 2021 | Model: RAV4 HV | Prod Date Range: [08/2020 - 12/2021] |
| Title: HYBRID / BATTERY CONTROL: HV BATTERY STACK (for LITHIUM-ION BATTERY): REMOVAL; 2021 MY RAV4 HV [08/2020 - 12/2021] | ||
REMOVAL
CAUTION / NOTICE / HINT
The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed and installed, or replaced during HV supply stack sub-assembly removal/installation are shown below.
Necessary Procedures After Parts Removed/Installed/Replaced
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Replaced Part or Performed Procedure |
Necessary Procedures |
Effect/Inoperative Function when Necessary Procedure not Performed |
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*: When performing learning using the Techstream.
Click here
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Auxiliary battery terminal is disconnected/reconnected |
Perform steering sensor zero point calibration |
Lane control system |
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Parking support brake system* |
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Pre-collision system |
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Lighting system (EXT) (w/ AFS) |
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Memorize steering angle neutral point |
Parking assist monitor system |
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Panoramic view monitor system |
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Reset back door close position |
Power back door system |
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Back door lock initialization |
Power door lock control system |
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HV battery status information cannot be updated |
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Current sensor offset learning |
DTCs are stored |
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Replacement of hybrid battery terminal block |
Perform high voltage fuse accumulated load history reset |
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CAUTION:
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Orange wire harnesses and connectors indicate high-voltage circuits. To prevent electric shock, always follow the procedure described in the repair manual.
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![2020 - 2025 MY RAV4 HV [06/2020 - ]; HYBRID / BATTERY CONTROL: HYBRID CONTROL SYSTEM (for LITHIUM-ION BATTERY): PRECAUTION](/t3Portal/stylegraphics/info.gif)
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To prevent electric shock, wear insulated gloves when working on wire harnesses and components of the high voltage system.
- The hybrid system has high-voltage circuits. Accidents, such as electric shock, or electric leaks may result if the hybrid system is not operated in a correct manner. Make sure to follow the correct procedure.
- When disposing of an HV battery or HV supply stack sub-assembly, make sure to return them through an authorized collection agent who is capable of handling them safely.
- Before returning an HV battery, make sure to perform a recovery inspection.
- Before returning an HV supply stack sub-assembly, make sure to perform a recovery inspection.
- Make a note of the output DTCs as some of them may be necessary for "Recovery Inspection" of the HV battery and HV supply stack sub-assemblies.
NOTICE:
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When replacing the No. 1 HV supply stack sub-assembly or No. 2 HV supply stack sub-assembly, it is necessary to check, adjust and equalize the SOC of the HV battery. Otherwise, the engine may run longer than normal, resulting in a decrease in fuel efficiency.
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After turning the power switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.
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PROCEDURE
1. READ VALUE USING TECHSTREAM
(a) Connect the Techstream to the DLC3.
(b) Turn the power switch on (IG).
(c) Enter the following menus: Powertrain / HV Battery / Data List / Hybrid/EV Battery Temperature 1 to 6.
Powertrain > Hybrid Control > Data List
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Tester Display |
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Hybrid/EV Battery Temperature 1 |
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Hybrid/EV Battery Temperature 2 |
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Hybrid/EV Battery Temperature 3 |
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Hybrid/EV Battery Temperature 4 |
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Hybrid/EV Battery Temperature 5 |
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Hybrid/EV Battery Temperature 6 |
(d) Read the Data List.
NOTICE:
If any of the temperatures listed in "Hybrid/EV Battery Temperature 1 to 6" are 50°C or more, leave the vehicle until the temperature drops to less than 50°C.
2. REMOVE HV BATTERY
Click here
3. REMOVE UPPER HV BATTERY COVER SUB-ASSEMBLY
Click here
4. REMOVE NO. 1 HV BATTERY HOSE
Click here
5. REMOVE HV BATTERY JUNCTION BLOCK ASSEMBLY
Click here
6. REMOVE HYBRID BATTERY TERMINAL BLOCK
Click here
7. REMOVE NO. 2 HYBRID BATTERY SHIELD SUB-ASSEMBLY
CAUTION:
Be sure to wear insulated gloves and protective goggles.
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(a) Remove the bolt, 3 nuts and No. 2 hybrid battery shield sub-assembly from the HV battery. |
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8. REMOVE NO. 1 HYBRID BATTERY COVER INTAKE DUCT
CAUTION:
Be sure to wear insulated gloves and protective goggles.
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(a) Remove the clip to disconnect the No. 1 hybrid battery cover intake duct from the HV battery. |
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(b) Disengage the claw of hybrid battery thermistor (sensor portion) and remove the No. 1 hybrid battery cover intake duct.
9. REMOVE BATTERY ECU ASSEMBLY
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10. REMOVE NO. 1 HV SUPPLY STACK SUB-ASSEMBLY
CAUTION:
Be sure to wear insulated gloves and protective goggles.
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(a) Disconnect the connector. NOTICE: Insulate each disconnected high-voltage connector with insulating tape. Wrap the connector from the wire harness side to the end of the connector. |
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(b) Disconnect the connector. |
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(c) Disengage the claw. |
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(d) Remove the 4 nuts and No. 1 HV supply stack sub-assembly. |
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11. REMOVE NO. 2 HV SUPPLY STACK SUB-ASSEMBLY
CAUTION:
Be sure to wear insulated gloves and protective goggles.
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(a) Remove the nut and disconnect the ground terminal. |
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(b) Disengage the clamp. |
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(c) Disengage the claw. |
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(d) Remove the 4 nuts and No. 2 HV supply stack sub-assembly. |
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12. PERFORM RECOVERY INSPECTION
(a) Before returning the HV supply stack sub-assembly, make sure to perform a recovery inspection.
Click here
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